Tanaka MOBY XL User manual

Service Manual
MOBY XL, SE-803
40cc PowerBoard Date 09-16-02
ISM, Inc. • 1028 4th Street SW • Auburn, WA 98001 • Phone: [phone] • Fax: [phone]
www.tanaka-usa.com [email protected]
Revision 001

www.tanaka-usa.com [e-mail]
Service Manual
Moby XL, SE-803
Table of Contents
Specifications 1
Torque Limits 1
Troubleshooting 2-3
Safety & Shop Practices 4
Routine Maintenance 4
Tools 5
General Inspection 6-8
Engine Repair 9-16
Brake System 17
Wheel Removal 18-19
Steering Head Components 20
Cables / Controls 21
Belt Adjustment / Replacement 22-23
Deck Removal 24
Warranty Statement 25

www.tanaka-usa.com 1 [e-mail]
Service Manual
Moby XL, SE-803
Specification Chart
Cylinder Plating Chrome
Piston Rings 2
Displacement (cc) 39.8
Horsepower 1.8
Bore x Stroke (mm) 39.8 x 32
Compression ratio 7.2:1
Maximum hp 1.8 @ 7500 rpm
Maximum kw 1.14 @ 8000 rpm
Maximum torque – kg-m (ft. lbs) 0.21 (1.5) @ 5500 rpm
Maximum RPM 11000
Idling RPM 3000 +/- 200
Starting System Recoil
Rotation (recoil side) Clockwise
Fuel capacity – cc (fl. oz) 1000 (33.8)
Fuel consumption – g/hp.hr (g/kw.hr) 345 (469)
Carburetor WYJ-224, Walbro
Clutch Diameter 76 mm
Spark Plug CJ7 (Champion) / BM7A (NGK)
Ignition System TCI
Spark Plug Electrode Gap .024
Second Coil Resistance 5.8 KΩ
Coil Air Gap .014 / .016
Engine Dimensions – LxWxH (mm) 170 x 260 x 270
Engine Weight – kg (lbs) 3.9 (8.6)
Scooter Weight 52 lbs.
Overall Length 48”
Height / (folded) 40” (17”)
Maximum Speed 24/25mph
Drive Ratio 10:1
Tire Air Pressure 50 psi (max)
Brakes (Front) Disc
Brakes (Rear) Friction
Tire Size / Type 10”/4 ply
Weight Capacity 270 lbs.
Fuel Gas/Oil 50:1
Spark Plug BPM6A (or equiv.)
Drive System Dual Belt
Ground Clearance 4.5”
Torque Limits
In. - Lb. N - M
Crankcase 40 4.5
Cylinder 40 4.5
Carburetor Insulator 45 5.0
Carburetor 38 4.2
Clutch Shoes 200 22.5
Flywheel 185 20.8
Ignition Coil 25 2.8
Spark Plug 150 16.8
Pawl Carrier 25 2.8
Fan Case 35 3.9
Muffler 50 5.6

www.tanaka-usa.com 2 [e-mail]
Service Manual
Moby XL, SE-803
Trouble Shooting
Engine Idles Poorly
Check Function of: Page No.
Clutch System ……………………….9
Ignition System: Spark Plug …………………….7, 8
Ignition System: Poor Spark ………………8, 11, 12
Fuel System : Fuel Tank …………...6, 8, 12, 13
Fuel System : Carburetor ………….7, 12, 13, 14
Air Filter ……………………….6
Exhaust System ………………7, 14, 15
Compression ……………………….7
Engine Lacks Power
Check Function of: Page No.
Clutch System ……………………….9
Ignition System: Poor Spark ………………8, 11, 12
Fuel System : Fuel Tank …………...6, 8, 12, 13
Fuel System : Carburetor ………….7, 12, 13, 14
Air Filter ……………………….6
Exhaust System ………………7, 14, 15
Compression ……………………….7
Engine Stops Suddenly
Check Function of: Page No.
Ignition System: No Spark …………...7, 8, 11, 12
Fuel System : Fuel Tank …………...6, 8, 12, 13
Fuel System : Carburetor ………………8, 12, 13
Compression ……………………….7
(Trouble Shooting cont.)
Engine Will Not Start
Check Function of: Page No.
Rewind Starter ………………6, 10, 11
Ignition System: No Spark …………...7, 8, 11, 12
Fuel System : Fuel Tank …………...6, 8, 12, 13
Fuel System : Carburetor ………………8, 12, 13
Air Filter ……………………….6
Exhaust System ………………7, 14, 15
Compression ……………………….7

www.tanaka-usa.com 3 [e-mail]
Service Manual
Moby XL, SE-803
Trouble Shooting cont.
Scooter vibrates
Check Function of: Page No:
Engine: …see page 2
Wheels: ………….………….6,7
Drive train: ………….………….8,9
Engine does not shut off with kill
button
Check Function of: Page No:
Engine: …see page 2
Cables / Controls: …………………….…8
Scooter does not adequately stop
Check Function of: Page No:
Brakes: ……………………….6
Scooter lacks power / acceleration
Check Function of: Page No:
Engine: …see page 2
Brakes: ………….……………6
Wheels: ………….……………6
Cables / Controls: …………………….…8
Drive train: ……………………..8,9

www.tanaka-usa.com 4 [e-mail]
Service Manual
Moby XL, SE-803
Safety & Shop Practices
oThe most successful and profitable service shops consistently seem to maintain the best habits of safety,
cleanliness, and orderly procedure. The following information is intended as a guide towards developing habits
that are necessary to accomplish satisfactory service work.
oMaintain a clean and orderly work area that is well lighted and adequately ventilated.
oTools, instruments, and parts needed for work should be clean and readily available before any job is started.
(Special tools available for servicing TANAKA equipment are listed in this manual.)
oScooter should be cleaned before repair work starts. Cleaning will often help reveal a source of trouble.
oBefore attempting to repair or operate any equipment, read and understand all information provided by the
instruction manual for the equipment.
oNever attempt to service a unit that is running or still heated from running unless it is specifically required by the
manufacturer’s instructions.
oWipe-up all spilled liquids immediately. Use non-flammable solvents for cleaning. Clean all parts before
reconditioning or reassembling.
oThoroughly inspect all parts for wear or damage. Replace all parts that show damage or excessive wear.
oAlways recondition and /or repair equipment strictly according to the Manufacturer’s specifications.
oBe sure all shields and safety devices are correctly installed before performing any final operating tests.
oAfter completion of any service or repair, the equipment should be thoroughly cleaned.
Routine Maintenance Guide
Each Use 20 Hrs. 25 Hrs. 100 Hrs.
Air Filter Clean O
All Fasteners Tighten O
Cooling Fins Clean O
Spark Arrestor Clean O
Fuel Filter Clean O
Spark Plug Clean O
Muffler & Exhaust Ports Clean O
Daily Weekly Monthly
All Fasteners Tighten O
Drive Belts Inspect/Adjust O
Brake (front) Inspect/Adjust O
Steering Head Inspect/Adjust O

www.tanaka-usa.com 5 [e-mail]
Moby XL. SE-803 Service Manual
Engine Diagnostic Tools
Engine Disassembly & Assembly Tools
Pin Remover
Part No. 009-29326-00
Flywheel Remover Set
1. Handle (006-29326-002)
2. Center Bolt (007-29326-000)
3. Flywheel Puller (006-2932-002)
4. Bolts (021-29355-00)
The following is a minimum list of tools required to service the Moby / Moby XL PowerBoard frames:
Allen wrenches - 3, 4, 5, 6mm
Wrenches - 8, 10, 13, 16, 17mm
Spark plug socket - 19mm
Crescent wrench Large
Screwdrivers - Slot / Phillips
Pliers Snap-Ring
Other tools may be preferable; however, complete service can be performed with the tools indicated above.
Compression Gauge
Part No. 27286
Pressure Tester
Part No. 070-2000W-500
Ohmmeter (Digital Type) Engine Tachometer (Digital Type)
Part No. 001-29000-000
Three Point Spark Tester

www.tanaka-usa.com 6 [email protected]om
Service Manual
Moby XL, SE-803
General Inspection
Once the engine is removed from the equipment, this is an ideal time to inspect for damage as well as potential
areas that may require repair. Some of the diagnostic evaluation cannot be effectively performed after
disassembly has begun.
Cover, Shroud, Fan Case
Inspect covers, shrouds, and fan case to identify damage or cracks due to
vibration, ground contact, etc. All of the shroud components are designed for
routing the flow of cooling air around the engine. Any broken or missing
components could lead to over heating of the engine during operation. Order
replacements as need.
Inspect the rubber spark plug boot for any damage that may cause a potential
shock hazard.
Ensure that the fuel tank is not damaged in any way due to possible ground
contact, excessive vibration, etc.
Any potential fuel leaks may be apparent during this initial inspection, as the
exposed fuel on the engine components may attract dirt. This provides a good
visual reference.
Recoil Starter
Ensure that the engine turns freely when the recoil starter is pulled, and
that the recoil starter rope retracts positively into the starter housing.
Fuel
If gasoline is present in the fuel tank, take the opportunity to empty it into a
clear container. This may reveal contamination such as water, (as
depicted in the photo – phase separation of gasoline and water is very
obvious), sediment, or the lack of two-cycle oil/fuel mixture.
Air Cleaner
Remove the air cleaner cover, and inspect the air cleaner element (A).
Ensure that it is clean and lightly oiled. Make sure the inside of the
housing that accommodates the cleaner element is free of dirt and dust.
The vented area of the crankcase, visible in the photo between the fuel
tank and the air cleaner body (B), allows air from the flywheel fins to be
circulated to the exterior of the engine and is critical to proper cooling.
Ensure that there is no debris within the vent fins that would impede the
circulation of air.

www.tanaka-usa.com 7 [email protected]om
Service Manual
Moby XL, SE-803
General Inspection Cont.
Choke Lever
Check to ensure that the choke lever (A) is able to rotate freely within the
air cleaner body, and that it has not been bent as to prevent a good seal
when closing over the air intake.
Spark Arrestor Screen
Remove the spark arrestor retaining screw and holder. Remove any
carbon deposits from the screen. If the screen has heavy deposits of
carbon build-up, replace it with a new part.
Spark Plug
Remove the spark plug rubber protection boot and high-tension lead, and
remove/inspect the spark plug.
Picture A depicts a spark plug that has a broken insulator. Picture B depicts a
spark plug that has fouled due to a rich fuel/oil mixture. Picture C depicts a plug
that has fouled due to carbon build-up. All of these conditions will prevent the
spark plug from functioning properly, and will require replacement.
Picture D depicts a plug characteristic of healthy running conditions. The
electrode should have a golden/tan color, and no damage is present.
Whenever the integrity of a spark plug comes into question, it should be replaced.
Whether the plug to be installed is new, used or cleaned, it should be checked for
correct electrode gap, which is .024”.
Cylinder Compression
Insert a compression gauge into the empty spark plug hole and pull the
recoil starter handle briskly several times, until the needle on the gauge
stops climbing. This reading represents the compression in the cylinder,
and is a good gauge of the piston rings ability to hold pressure. The unit
will struggle to run with compression less than approximately 90 psi. Such
low readings indicate the need for service to the cylinder, piston or piston
rings.

www.tanaka-usa.com 8 [email protected]om
Service Manual
Moby XL, SE-803
General Inspection Cont.
Spark Testing
While the rubber spark plug boot / high-tension lead are removed from the
spark plug, this is an ideal time to test the quality of the current being
delivered to the spark plug. Insert a three point spark tester into the spark
plug boot and briskly pull the recoil starter. The tester should reveal a strong
spark with a blue color. Lack of spark, weak spark, or yellow spark may
indicate a problem with another electrical component within the engine.
Ignition Coil Testing
Connect an ohmmeter to the ignition coil with one lead inserted into the spark
plug boot and the other making contact with the cylinder fins of the engine
(as shown).
Secondary resistance, when tested this way, should indicate 5.8 (+/- 1) KΩ.
If the reading is not within this range, replace with a new coil, (previous tests
for spark using a three point tester should have indicated a weak spark or
none at all).
If the reading is within range, and still weak or no spark is evident, replace
the ignition coil.
Fasteners
Check to ensure that all fasteners are tight prior to disassembly.
Loosening of fasteners on the carburetor side may cause erratic running
conditions, or even engine failure.
It’s always best to know if fasteners are properly torqued prior to engine
service, as problematic running conditions may be the result.
Fuel Filter
Using a hooked wire, reach into the filler neck of the fuel tank, and grasp the
fuel line. Gently pull the fuel line, with the fuel filter attached, through the filler
neck. The filter should be white in color and should be compressible between
two fingers. If it appears discolored or hard, replace with a new one.